2004 YAMAHA VERSITY 300 check engine

PERIODIC MAINTENANCE AND MINOR REPAIR
6
•Check operation, fluid level and vehicle for fluid leakage.
√√√√√ √7 * Rear brake(See NOTE on page 6-4.)
•Replace brake pads. Whenever worn to the limit
8 * Brake hoses•Check for cracks or damage.√√√√ √•Replace. (See NOTE on page 6-4.) Every 4 years
9 * Wheels•Check runout and for damage.√√√√
•Check tread depth and for damage.
10 * Tires•Replace if necessary.
√√√√ √
•Check air pressure.
•Correct if necessary.
11 * Wheel bearings•Check bearing for looseness or damage.√√√√
12 * Steering bearings•Check bearing play and steering for roughness.√√√√√•Lubricate with lithium-soap-based grease. Every 20,000 km
13 * Chassis fasteners•Make sure that all nuts, bolts and screws are
√√√√ √
properly tightened.
14 Sidestand, Centerstand•Check operation.
√√√√ √
•Lubricate.
15 * Sidestand switch•Check operation.√√√√√ √
16 * Front fork•Check operation and for oil leakage.√√√√
17 * Shock absorber assemblies•Check operation and shock absorbers for oil leakage.√√√√
18 * Carburetor•Adjust engine idling speed.√√√√√ √
ODOMETER READING (x 1,000 km)
NO. ITEMCHECK OR MAINTENANCE JOB
1
ANNUAL
CHECK
10 20 30 40
6-3

PERIODIC MAINTENANCE AND MINOR REPAIR
6
•Change. (See page 3-7 for more information about the√When the oil change indicator comes on19 Engine oil oil change indicator)( Every 3000 km)
•Check oil level and vehicule for oil leakage. Every 3,000 km√
20 * Engine oil strainer•Clean.√
21 * Cooling system•Check coolant level and vehicule for coolant leakage.√√√√ √•Change. Every 3 years
22Final transmission oil•Check vehicle for oil leakage.√√ √•Change.√√√
23 * V-belt•Replace. Every 20,000 km
24 *Front and rear brake
•Check operation.√√√√√ √
switches
25 Moving parts and cables•Lubricate.√√√√ √
Throttle grip housing•Check operation and free play.
26 *
and cable•Adjust the throttle cable free play if necessary.√√√√ √
•Lubricate the throttle grip housing and cable.
27 *Lights, signals•Check operation.
√√√√√ √
and switches•Adjust headlight beam.
ODOMETER READING (x 1,000 km)
NO. ITEMCHECK OR MAINTENANCE JOB
1
ANNUAL
CHECK
10 20 30 40
EAU03884*
NOTE :
•The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
•Hydraulic brake service
•Regularly check and, if necessary, correct the brake fluid level.
•Every two years change the brake fluid.
•Replace the brake hoses every four years and if cracked or damaged.
6-4

PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03620
Checking the spark plug
The spark plug is an important engine
component, which is easy to check.
Since heat and deposits will cause any
spark plug to slowly erode, the spark
plug should be removed and checked
in accordance with the periodic main-
tenance and lubrication chart. In addi-
tion, the condition of the spark plug can
reveal the condition of the engine.
To remove the spark plug
1. Remove cowling B. (See page 6-
8 for cowling removal and instal-
lation procedures.)
2. Remove the spark plug cap.
1. Spark plug
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12
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Panel E
To remove the panel
Remove the screw, and then pull the
panel off as shown.
To install the panel
Place the panel in the original position,
and then install the screw.
1. Panel E
2. Screw

PERIODIC MAINTENANCE AND MINOR REPAIR
6 3. Remove the spark plug as shown,
with the spark plug wrench
included in the owner's tool kit.To check the spark plug
1. Check that the porcelain insulator
around the center electrode of the
spark plug is a medium-to-light
tan (the ideal color when the scoo-
ter is ridden normally).
NOTE :
If the spark plug shows a distinctly
different color, the engine could be
defective. Do not attempt to diagnose
such problems yourself. Instead, have
a Yamaha dealer check the scooter.
2. Check the spark plug for electrode
erosion and excessive carbon or
other deposits, and replace it if
necessary.
Specified spark plug:
DR8EA (NGK)To install the spark plug
1. Measure the spark plug gap with
a wire thickness gauge and, if
necessary, adjust the gap to
specification.
Spark plug gap:
0.6 – 0.7 mm
2. Clean the surface of the spark
plug gasket and its mating sur-
face, and then wipe off any grime
from the spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then
tighten it to the specified torque.
1. Spark plug wrencha. Spark plug gap
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a
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PERIODIC MAINTENANCE AND MINOR REPAIR
6Tightening torque:
Spark plug:
17.5 Nm (1.75 m
•kg)
NOTE :
If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4 – 1/2 turn
past finger tight. However, the spark
plug should be tightened to the
specified torque as soon as possible.
4. Install the spark plug cap.
5. Install the cowling.
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Engine oil
The engine oil level should be checked
before each ride. In addition, the oil
must be changed at the intervals
specified in the periodic maintenance
and lubrication chart and when the oil
change indicator comes on.To check the engine oil level
1. Place the scooter on the
centerstand.
NOTE :
Make sure that the scooter is positioned
straight up when checking the oil level.
A slight tilt to the side can result in a
false reading.
2. Start the engine, warm it up for
several minutes, and then turn it
off.

PERIODIC MAINTENANCE AND MINOR REPAIR
6
1. Engine oil filler cap
2. Maximum level mark
3. Minimum level mark1. Engine oil drain bolt
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1
3
21
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3. Wait a few minutes until the oil
settles, remove the oil filler cap,
wipe the dipstick clean, insert it
back into the oil filler hole (without
screwing it in), and then remove
it again to check the oil level.
NOTE :
The engine oil should be between the
minimum and maximum level marks.4. If the engine oil is below the mini-
mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.
5. Insert the dipstick into the oil filler
hole, and then tighten the oil filler
cap.
To change the engine oil
1. Start the engine, warm it up for
several minutes, and then turn it off.
2. Place an oil pan under the engine
to collect the used oil.
3. Remove the engine oil filler cap
and the engine oil drain bolt to
drain the oil from the crankcase.
11
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PERIODIC MAINTENANCE AND MINOR REPAIR
6CAUTION:
1. Engine oil drain bolt
2. Washer
6-15
12ZAUM0129
4. Check the washer for damage and
replace it if necessary.
5. Install the washer and the engine
oil drain bolt, and then tighten the
drain bolt to the specified torque.
Tightening torque:
Engine oil drain bolt:
20 Nm (2.0 m
•kgf)
NOTE :
Make sure that the washer is properly
seated.6. Add the specified amount of the
recommended engine oil, and
then install and tighten the oil filler
cap.
Recommended engine oil:
See page 8-1.
Oil quantity:
Periodic oil change:
1.2 L
Total amount (dry engine):
1.4 L7. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking,
immediately turn the engine off
and check for the cause.
8. Reset the oil change indicator.
(See page 3-7 for details.)
ECA00140
•Do not use oils with a diesel
specification of "CD" or oils of a
higher quality than specified. In
addition, do not use oils labeled
"ENERGY CONSERVING II" or
higher.
•Be sure no foreign material
enters the crankcase.

PERIODIC MAINTENANCE AND MINOR REPAIR
6
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Final transmission oil
The final transmission case must be
checked for oil leakage before each
ride. If any leakage is found, have a
Yamaha dealer check and repair the
scooter. In addition, the final transmis-
sion oil must be changed as follows at
the intervals specified in the periodic
maintenance and lubrication chart.
1. Start the engine, warm it up by
riding the scooter for several mi-
nutes, and then stop the engine.
2. Place the scooter on the
centerstand.
3. Place an oil pan under the final
transmission case to collect the
used oil.4. Remove the oil filler cap and drain
bolt to drain the oil from the final
transmission case.
5. Install the final transmission oil
drain bolt, and then tighten it to
the specified torque.
Tightening torque:
Final transmission oil drain bolt:
22 Nm (2.2 m
•kgf)
6. Add the specified amount of the
recommended final transmission
oil, and then install and tighten the
oil filler cap.
1. Final transmission oil filler cap1. Final transmission oil drain bolt
Recommended final transmission
oil:
See page 8-2.
Oil quantity:
0.25 L
EWA00062
•Make sure that no foreign
material enters the final trans-
mission case.
•Make sure that no oil gets on
the tire or wheel.
7. Check the final transmission case
for oil leakage. If oil is leaking,
check for the cause.
WARNING
6-16
1
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